Publications

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The use of solid particles as a heat-transfer fluid and thermal storage media for concentrating solar power is a promising candidate for meeting levelized cost of electricity (LCOE) targets for next-generation CSP concepts. Meeting these cost targets for a given system concept will require optimization of the particle heat-transfer fluid with simultaneous consideration of all system components and operating conditions. This paper explores the trade-offs in system operating conditions and particle thermophysical properties on the levelized cost of electricity through parametric analysis. A steady-state modeling methodology for design point simulations dispatched against typical meteorological year (TMY) data is presented, which includes computationally efficient submodels of a falling particle receiver, moving packed-bed heat exchanger, storage bin, particle lift, and recompression supercritical CO2 (sCO2) cycle. The components selected for the baseline system configuration presents the most near-term realization of a particle-based CSP system that has been developed to date. However, the methodology could be extended to consider alternative particle receiver and heat exchanger concepts. The detailed system-level model coupled to component cost models is capable of propagating component design and performance information directly into the plant performance and economics. The system-level model is used to investigate how the levelized cost of electricity varies with changes in particle absorptivity, hot storage bin temperature, heat exchanger approach temperature, and sCO2 cycle operating parameters. Trade-offs in system capital cost and solar-to-electric efficiency due to changes in the size of the heliostat field, storage bins, primary heat exchanger, and receiver efficiency are observed. Optimal system operating conditions are reported, which approach levelized costs of electricity of $0.06 kWe-1hr-1

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In order for Concentrating Solar Power plants (CSP) to achieve the desired cost breakpoint, significant improvement in performance is required resulting in the need to increase temperatures of fluid systems. A US DOE Small Business Voucher project was established at Sandia to explore the performance characteristics of Ceramic Tubular Products (CTP) silicon carbide TRIPLEX tubes in key categories relating to its performance as a solar receiver in next generation CSP plants. Along these lines, the following research tasks were completed : (1) Solar Spectrum Testing, (2) Corrosion Testing in Molten Chloride Salt, (3) Mechanical Shock Testing, and (4) Thermal Shock Testing. Through the completion of these four tasks, it has been found that the performance of CTP's material across all of these categories is promising, and merits further investigation beyond this initial investigation. Through 50 solar aging cycles, the CTP material exhibited excellent stability to high temperatures in air, exhibited at or above 0.95 absorptance, and had measured emittances within the range of 0.88-0.90. Through molten salt corrosion testing at 750degC it was found that SiC exhibits significantly lower mass change (-- 90 times lower) than Haynes 230 during 108 hours of salt exposure. The CTP TRIPLEX material performed significantly better than the SiC monolithic tube material in mechanical shock testing, breaking at an average height of 3 times that for the monolithic tubes. Through simulated rain thermal shock testing of CTP composite tubes at 800degC it was found that CTP's SiC composite tubes were able to survive thermal shock, while the SiC monolithic tubes did not. ACKNOWLEDGEMENTS * US Department of Energy Office of EERE for sponsorship of this project * Andrew Dawson of the DOE Office of EERE for Project Management, including the excellent technical insights that he provided throughout the project * Ken Armijo lead the Thermal Shock Testing activities * Cliff Ho and Julius Yellowhair led the Solar Spectrum Testing activities * Jeff Halfinger prepared the CTP specimens for each of the research tasks * Herb Feinroth provided guidance and input into the preparation for the test specimens and the associated research tasks * Alan Kruizenga collaborated with CTP to apply for and be awarded this project from DOE EERE. The scope for the project was developed by Alan together with CTP. * Rio Hatton and Jesus Ortega (student interns) helped with portions of the solar simulator testing, reflectance/emittance data collection, and image (including microscope) collection. * Kent Smith helped design and fabricate the high temperature molten salt corrosion setup * Jeff Chames and Javier Cebrian completed the microscopy for the molten salt corrosion test specimens * Amy Bohinsky (student intern) and Kevin Nelson helped complete the mechanical shock testing for the monolithic and composite tubes, including organizing the results for the final report. * Josh Christian and Daniel Ray helped with portions of the Thermal Shock Testing * Mark Stavig completed the polyethylene plug testing associated with the Thermal Shock Testing

Falling particle receivers are an emerging technology for use in concentrating solar power systems. In this work, quartz tubes cut in half to form tube shells (referred to as quartz half-shells) are investigated for use as a full or partial aperture cover to reduce radiative and advective losses from the receiver. A receiver subdomain and surrounding air volume are modeled using ANSYS® Fluent®. The model is used to simulate fluid dynamics and heat transfer for the following cases: (1) open aperture, (2) aperture fully covered by quartz half-shells, and (3) aperture partially covered by quartz half-shells. We compare the percentage of total incident solar power lost due to conduction through the receiver walls, advective losses through the aperture, and radiation exiting out of the aperture. Contrary to expected outcomes, simulation results using the simplified receiver subdomain show that quartz aperture covers can increase radiative losses and, in the partially covered case, also increase advective losses. These increased heat losses are driven by elevated quartz half-shell temperatures and have the potential to be mitigated by active cooling and/or material selection.

Solid particle receivers provide an opportunity to run concentrating solar tower receivers at higher temperatures and increased overall system efficiencies. The design of the bins used for storing and managing the flow of particles creates engineering challenges in minimizing thermomechanical stress and heat loss. An optimization study of mechanical stress and heat loss was performed at the National Solar Thermal Test Facility at Sandia National Laboratories to determine the geometry of the hot particle storage hopper for a 1 MWt pilot plant facility. Modeling of heat loss was performed on hopper designs with a range of geometric parameters with the goal of providing uniform mass flow of bulk solids with no clogging, minimizing heat loss, and reducing thermomechanical stresses. The heat loss calculation included an analysis of the particle temperatures using a thermal resistance network that included the insulation and hopper. A plot of the total heat loss as a function of geometry and required thicknesses to accommodate thermomechanical stresses revealed suitable designs. In addition to the geometries related to flow type and mechanical stress, this study characterized flow related properties of CARBO HSP 40/70 and Accucast ID50-K in contact with refractory insulation. This insulation internally lines the hopper to prevent heat loss and allow for low cost structural materials to be used for bin construction. The wall friction angle, effective angle of friction, and cohesive strength of the bulk solid were variables that were determined from empirical analysis of the particles at temperatures up to 600°C.

A 1 MWt falling particle receiver prototype was designed, built and is being evaluated at Sandia National Laboratories, National Solar Thermal Test Facility (NSTTF). The current prototype has a 1 m2 aperture facing the north field. The current aperture configuration is susceptible to heat and particle losses through the receiver aperture. Several options are being considered for the next design iteration to reduce the risk of heat and particle losses, in addition to improving the receiver efficiency to target levels of ~90%. One option is to cover the receiver aperture with a highly durable and transmissive material such as quartz glass. Quartz glass has high transmittance for wavelengths less than 2.5 microns and low transmittance for wavelengths greater than 2.5 microns to help trap the heat inside the receiver. To evaluate the receiver optical performance, ray-tracing models were set up for several different aperture cover configurations. The falling particle receiver is modeled as a box with a 1 m2 aperture on the north side wall. The box dimensions are 1.57 m wide x 1.77 m tall x 1.67 m deep. The walls are composed of RSLE material modeled as Lambertian surfaces with reflectance of either 0.9 for the pristine condition or 0.5 for soiled walls. The quartz half-shell tubes are 1.46 m long with 105 mm and 110 mm inner and outer diameters, respectively. The half-shell tubes are arranged vertically and slant forward at the top by 30 degrees. Four configurations were considered: concave side of the half-shells facing away from the receiver aperture with (1) no spacing and (2) high spacing between the tubes, and concave side of the half-shells facing the aperture with (3) no spacing and (4) high spacing between the tubes. The particle curtain, in the first modeling approach, is modeled as a diffuse surface with transmittance, reflectance, and absorptance values, which are based on estimates from previous experiments for varying particle flow rates. The incident radiation is from the full NSTTF heliostat field with a single aimpoint at the center of the receiver aperture. The direct incident rays and reflected and scattered rays off the internal receiver surfaces are recorded on the internal walls and particle curtain surfaces as net incident irradiance. The net incident irradiances on the internal walls and particle curtain for the different aperture cover configuration are compared to the baseline configuration. In all cases, just from optical performance alone, the net incident irradiance is reduced from the baseline. However, it is expected that the quartz half-shells will reduce the convective and thermal radiation losses through the aperture. These ray-tracing results will be used as boundary conditions in computational fluid dynamics (CFD) analyses to determine the net receiver efficiency and optimal configuration for the quartz half-shells that minimize heat losses and maximize thermal efficiency.

Experiments for measuring the heat transfer coefficients and visualization of dense granular flows in rectangular vertical channels are reported. The experiments are directed at the development of a moving packed-bed heat exchanger to transfer thermal energy from solar-heated particles to drive a supercritical carbon dioxide (sCO2) power cycle. Particle-wall heat transfer coefficients are found to agree with Nusselt number correlations for plug flow in a parallel plate configuration. The plate spacing and particle properties in the prototype design result in experimentally measured particle-wall heat transfer coefficients of 200 W/m2-K at intermediate temperature and are expected to be higher at elevated temperature due to improved packed bed thermal conductivity. The high-temperature (600°C) visualization experiments indicate that uniform particle flow distribution through the vertical channels of a shell-and-plate heat exchanger can be achieved through a mass flow cone particle feeder. Uniform drawdown was experienced for both 77° and 72° feeder angles over a range of particle mass flow rates between 0.05 and 0.175 kg/s controlled by a slide gate to modulate the outlet flow cross-sectional area.

This paper evaluates a novel receiver design concept that implements photovoltaic (PV) cells on heat shields and bellows shields to capture optical spillage from central receiver and parabolic trough concentrating solar power (CSP) plants, generating electricity from concentrated light that would otherwise be wasted. A combination of conventional silicon and multi-junction concentrating PV (CPV) cells were evaluated to accommodate regions of both high and low solar fluxes on the shields. Estimates from existing CSP plants indicate that the irradiance on central-receiver heat shields can be well over 100 kW/m2 near the receiver tubes, but lower fluxes can occur in distant regions or in parabolic trough applications. A technoeconomic study was performed to estimate the levelized cost of energy (LCOE) for these systems as a function of several cost and performance factors, such as irradiance, PV cell type, and cooling conditions.

Solar glare reflections and avian solar-flux hazards are an important concern for concentrating solar installations. Reflected sunlight from "standby" heliostats has been noted by pilots as potentially hazardous, and reports of birds being singed by concentrated sunlight has created concern. This paper presents the Tower Illuminance Model ("TIM"), a software application developed to investigate glare and avian-flux hazards at concentrating solar power towers in a convenient and interactive manner. TIM simulates a field of heliostats in standby mode, wherein sunlight is not reflected toward the central receiver but at some location in the airspace around the receiver. The user can select a range of aiming strategies and field configurations and can navigate the simulated airspace above the heliostat field in real-time using an interactive 3D interface. As the user "flies" through the airspace, TIM calculates the irradiance, glare hazard, and potential avian flux hazard. TIM is currently undergoing validation and industry testing.

A computational fluid dynamics model of a 50 MWe falling particle receiver has been developed to evaluate the ability of the receiver concept to scale to intermediate sized systems while maintaining high thermal efficiencies. A compatible heliostat field for the receiver was generated using NREL's SolarPILOT, and this field was used to calculate the irradiance on the receiver at seventeen different dates and times throughout the year. The thermal efficiency of the receiver was evaluated at these seventeen different samples using the CFD model and found to vary from 83.0 - 86.8%. An annualized thermal efficiency was calculated from the samples to be 85.7%. A table was also generated that summarized this study along with other similar CFD studies on falling particle receivers over a wide ranges of scales.

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This report describes software tools that can be used to evaluate and mitigate potential glare and avian-flux hazards from photovoltaic and concentrating solar power (CSP) plants. Enhancements to the Solar Glare Hazard Analysis Tool (SGHAT) include new block-space receptor models, integration of PVWatts for energy prediction, and a 3D daily glare visualization feature. Tools and methods to evaluate avian-flux hazards at CSP plants with large heliostat fields are also discussed. Alternative heliostat standby aiming strategies were investigated to reduce the avian-flux hazard and minimize impacts to operational performance. Finally, helicopter flyovers were conducted at the National Solar Thermal Test Facility and at the Ivanpah Solar Electric Generating System to evaluate the alternative heliostat aiming strategies and to provide a basis for model validation. Results showed that the models generally overpredicted the measured results, but they were able to simulate the trends in irradiance values with distance. A heliostat up-aiming strategy is recommended to alleviate both glare and avian-flux hazards, but operational schemes are required to reduce the impact on heliostat slew times and plant performance. Future studies should consider the trade-offs and collective impacts on these three factors of glare, avian-flux hazards, and plant operations and performance.